Casing for holding a fluid for a heat exchanger, method for producing a casing of this type and heat exchanger

ABSTRACT

The invention relates to a casing for holding a coolant for a heat exchanger ( 1 ) for motor vehicles, said casing having two side walls ( 22, 24,  and  22   a,    24   a ), two front walls ( 26, 28  and  26   a,    28   a ), a cover ( 18  and  18   a ) and a base ( 20  and  20   a ) lying opposite the cover ( 18  and  18   a ), said base being provided with one or more openings ( 60 ) for receiving tubes, According to the invention, the casing consists of a single formed, in particular folded, shaped part, said formed shaped part, in particular a sheet metal blank, forming the two side walls ( 22, 24  and  22   a,    24   a ), the two front walls ( 26, 28  and  26   a,    28   a ), the cover ( 18  and  18   a ) and the base ( 20  and  20   a ).

The invention relates to a casing for holding a fluid for a heat exchanger, to a method for producing such a casing, and also to a heat exchanger.

From EP 1 139 054 B1, a casing is known for holding a fluid for a heat exchanger.

This known casing has a base with receptacle slots for connecting tubes or flat tubes and a cover arranged opposite this base. This cover is formed in one piece with the two end walls.

The invention is based on the problem of devising an economical and easy-to-produce fluid casing for a heat exchanger.

This problem is solved by a casing for holding a fluid for a heat exchanger, by a method for producing such a casing for holding a fluid, and also by a heat exchanger with the features of the corresponding independent claims.

Advantageous embodiments and refinements are the subject matter of the subordinate claims. The subject matter of the subordinate claims relates both to casings according to the invention for holding a fluid for a heat exchanger, to the method according to the invention for producing such a casing, and also to the heat exchanger according to the invention.

According to the invention, in particular, a casing for holding a fluid is proposed, wherein the fluid is preferably a coolant, which is why, without it representing a limitation, it is also designated below as a coolant casing.

The coolant casing that is advantageously designed for a heat exchanger, in particular, for a heat exchanger of a motor vehicle, has two side walls, two end walls, a cover, and also a base.

It is provided, in particular, that the aforementioned walls, i.e., the end walls, the side walls, the base, and the cover define an inner space of the coolant casing.

According to the invention, the coolant casing is made from only one shaped, in particular, folded, molded part, in particular, punched sheet metal that forms the two side walls, the two end walls, the cover, and the base.

In an especially preferred way, the shaped, in particular, folded, molded part is soldered, in particular, solder-plated.

It can also be further preferably provided that, for the coolant casing, the side walls are arranged at a distance to each other and, advantageously, parallel to each other, especially perpendicular to a longitudinal direction of the casing or coolant casing. A corresponding situation applies for the side walls that are then arranged, in particular, in the longitudinal direction of the coolant casing. The cover and the base are also arranged, in particular, spaced apart relative to each other.

In particular, the molded part is punched sheet metal that can be folded across or along given folding or bending or flap lines to form the coolant casing, wherein the two side walls, the two end walls, the cover, and the base are formed.

The folding or bending or flap lines are here each arranged preferably in the transition regions between two of the walls mentioned above.

Optionally, the molded part can be processed before or after the folding by other shaping methods, such as a drawing method, in particular, a deep-drawing method, and/or a hydro-shaping method, and/or molding compression methods.

Furthermore, at least one of the side walls (22, 24 or 22 a, 24 a) has an indentation, in particular, for holding a port, especially a port with a large diameter.

Here, it can be preferably provided that the cover has a corresponding bulge that is essentially adapted to the profile of the side walls, in particular, to the indentation for holding the port in the side walls.

The base advantageously has a bulged configuration.

In the base, one or more receptacle openings for tubes could be provided, in particular, for connecting tubes. The tubes could be shaped, for example, as flat tubes and could be a component of a tube-rib block. It can be further provided that for each separate tube, a separate opening is provided in the base. However, a large area opening for holding all of the tubes of the tube-rib block could also be provided.

Preferably, it could also be provided that one of the above-mentioned walls defining the inner space of the coolant casing has a bracket and/or assembly that is arranged, in particular, on the side and/or that can be angled.

The one or more brackets and/or assemblies can be angled such that they are arranged essentially parallel to a connection wall and/or they are connected to this connection wall, in particular, by a solder connection.

Also, in the molded part, one, especially, several essentially triangular recesses could each be formed in a transition region between two walls. This could be provided, in particular, for simplifying processing of the one-piece molded part, in particular, bending or folding or flapping.

Furthermore, it could be provided that a recess is provided in the cover in which extends a separating wall that divides the inner space of the coolant casing into sub-chambers.

In a preferred shape, the cover has a U-shaped form in cross section, so that two spaced-apart flanges are formed that are connected to a cover base by means of a connection section lying in between. This U-shape could be formed, for example, from vertical or approximately vertical sections. Rounded shapes are also preferred.

The cover could be arranged in the coolant casing so that the flanges grip over the side walls of the coolant casing from the outside or from the inside.

In an especially preferred shape, brackets that have, in an especially preferred way, an arc-shaped construction extend from the flanges of the U-shape that are also designated as legs. These brackets advantageously grip over the side walls of the coolant casing. Here it can be preferably provided that the cover is arranged in the coolant casing so that the flanges project from the connection section in the direction away from the base of the coolant casing and the brackets that are then bent outwardly connect to the ends located in this direction, so that they grip over the side walls of the coolant casing from the outside. It is especially provided that—viewed in the longitudinal direction of the coolant casing—several such brackets spaced apart from each other are provided on the cover.

In the method according to the invention for producing a casing for holding a fluid, such as a coolant, for a heat exchanger, in particular, for producing the coolant casing according to the invention, an inner space of the casing is defined by walls, in particular by two side walls, two end walls, a cover, and a base arranged opposite the cover.

In the production of the coolant casing, in a first step, a one-piece part, in particular, punched sheet metal, is produced by a separating method, in particular, by punching, wherein the one-piece part contains the walls defining the inner space of the casing.

In a second step, the one-piece part is shaped into an essentially closed casing, in particular, bent or folded across or along given bending or folding lines.

In a third step, the shaped, one-piece part is connected for forming the coolant casing, in particular, by solder-plating.

It is especially advantageous when it is folded across an end wall or across both end walls.

In an especially preferred way, it could also be provided that, in the one-piece part, in particular, in a region of the one-piece part that forms the base in the casing, one or more openings for holding tubes, in particular, connecting tubes, such as flat tubes, is or are formed.

The one or more openings for holding tubes could be formed before the second step, in particular, after the first step or at the same time as the first step.

Furthermore, it is especially advantageous when one or more tubes, in particular, connecting tubes, such as flat tubes, are inserted into the one or more openings, in particular, before the second step.

In a refinement, it could also be provided that the one-piece part is processed by additional shaping methods, in particular, drawing, especially deep drawing, and/or hydro-forming and/or mold pressing.

The heat exchanger, in particular, a cooler for a motor vehicle, has a tube-rib block and a casing or coolant casing according to the invention, wherein tubes of the tube-rib block in the region of the base of the casing open into this region.

Below, embodiment examples of the invention will be explained with reference to the figures. Shown are:

FIG. 1 a, an example heat exchanger according to the invention that is formed as a cooler with an example casing according to the invention for holding a fluid, wherein the casing is here a coolant casing;

FIG. 1 b, the heat exchanger according to FIG. 1 in a view from above;

FIG. 1 c, a side view of the heat exchanger according to FIG. 1;

FIG. 2 a, a unit of a coolant casing of the heat exchanger according to FIG. 1, which has two side walls, two end walls, and a base in a top view onto one of the two side walls;

FIG. 2 b, the unit according to FIG. 2 a in a top view onto the base;

FIG. 2 c, the unit according to FIG. 2 a in a top view onto the other of the two side walls;

FIG. 2 d, a partial section view along line A-A from FIG. 2 b;

FIG. 3 a, an example shape of a cover of a casing according to the invention in side view, wherein this shape of the cover is given, in particular, for the shape according to FIGS. 1 a to 3 i;

FIG. 3 b, the cover according to FIG. 3 a in a top view;

FIG. 3 c, the cover according to FIG. 3 a in a three-dimensional, perspective view from below;

FIG. 3 d, a section along line C-C from FIG. 3 a;

FIG. 3 e, a section along line D-D from FIG. 3 b in partial view;

FIG. 3 f, a section along line E-E from FIG. 3 b;

FIG. 3 g, a section along line F-F from FIG. 3 a;

FIG. 3 h, a section along line G-G from FIG. 3 a;

FIG. 3 i, a perspective view onto a section of the cover provided with brackets according to FIG. 3 a from above;

FIG. 4, a perspective diagram of a partially completed or folded, one-piece unit 16 or 16 a of the casing according to the invention from FIGS. 1 a-3 i;

FIG. 5, a top view onto a base plate that is punched from sheet metal and that forms the partially completed or folded one-piece unit 16 or 16 a shown in FIG. 4 for the casing according to the invention from FIGS. 1 a-3 i.

FIGS. 1 a-5 show an example embodiment of a heat exchanger 1 according to the invention with a casing according to the invention produced by folding a one-piece part for holding a fluid. This casing for holding a fluid is, in particular, a coolant casing, so that, for simplification, the term coolant casing is used below.

The heat exchanger 1 has a first coolant casing 10 and a second coolant casing 12 spaced apart from this first casing, and also a tube-rib block 14 that is arranged between these coolant casings 10, 12.

The tube-rib block 14 has a plurality of connecting tubes that are oriented in parallel and that are shaped, in this example, as flat tubes. Between these connecting tubes, tube intermediate spaces are formed—perpendicular to the longitudinal direction of these connecting tubes—in which ribs are arranged in a known way, such that the tube-rib block can carry a flow of air perpendicular to the plane formed by the tube arrangement.

The connecting tubes of the tube-rib block 14 each open with a first end into the first coolant casing 10 and with their second end into the second coolant casing 12.

The coolant casings 10, 12 are each formed from a one-piece, folded (sheet metal) part 16 or 16 a and consequently have only one essentially closed (casing-shaped) unit 16 or 16 a.

The unit 16 or 16 a has a cover 18 or 18 a and a base 20 or 20 a on the side opposite the cover 18 or 18 a. Furthermore, the unit 16, 16 a has a first side wall 22 or 22 a, a second side wall 24, 24 a opposite this first side wall 22, 22 a, a first end wall 26 or 26 a defining the inner space of the coolant casing 10 or 12 in a first orientation of its longitudinal direction (indicated by the double arrow 30), and also a second wall 28 or 28 a defining this inner space of the first 10 or second coolant casing in the opposite orientation (the longitudinal direction 30).

The cover 18 or 18 a, the side walls 22, 24 or 22 a, 24 a, and also the base 20 or 20 a also define the inner space of the coolant casing 10 or 12.

FIGS. 4 and 5 show how the cover 18 or 18 a, the base 20 or 20 a, the side walls 22, 24 or 22 a, 24 a, and the end walls 26, 28 or 26 a, 28 a join together in the one-piece part 16 or 16 a and are or will be folded to form the folded unit 16, 16 a or the coolant casing 10 or 12.

Here it shall be noted that other basic shapes with other connections of the cover 18 or 18 a, base 20 or 20 a, side walls 22, 24 or 22 a, 24 a, and end walls 26, 28 or 26 a, 28 a could also be realized in the one-piece part 16 or 16 a—consequently with different folds or with different folding sequences.

In the embodiment according to FIGS. 1 a-5, which could also be realized differently, the heat exchanger 1, which is also designated or could be formed as a cooler, is divided functionally into two (sub) coolers or (sub) heat exchangers. For this purpose, viewed in the longitudinal direction 30, a separating wall 32 or 24 is provided at the same height in the two coolant casings 10, 12, each perpendicular to this longitudinal direction 30. Additional separating walls arranged in the coolant casings 10, 12 at different heights in the longitudinal direction 30 could also be provided (that are not shown in the figure) that cause a serpentine-like deflection of the coolant.

It could be provided, for example, that the upper sub-cooler in FIG. 1 a is a component of a high-temperature cooling circuit and the lower sub-cooler 38 is a component of a low-temperature circuit.

A main port 40 or 42 opens into the first coolant casing 10 and also into the second coolant casing 12, wherein coolant can flow into the upper sub-cooler 36 via one of these main ports 40, 42 and wherein the coolant can flow out from the upper sub-cooler 36 again via the other of these ports 40, 42.

Accordingly, the lower sub-cooler 38 has a port 44 opening into the first coolant casing 10 and also a port 46 opening into the second coolant casing 12, wherein here coolant can also flow through one of these ports 44, 46 into the lower sub-cooler 38 and can flow out from this lower sub-cooler 38 through the other of these ports 46, 44.

In the region of the first coolant casing 10 there is furthermore a drain plug 48 for draining coolant. Furthermore, in the region of the first coolant casing 10, here in the region of the upper end, there is a port 50 for filling with coolant and/or venting.

FIG. 1 b shows a top view onto the shape according to FIG. 1 a from above.

FIG. 1 c shows a side view of the shape according to FIG. 1 a from the left.

FIGS. 2 a-2 d show different views of the first coolant casing 10 or the unit 16 closed by folding in this first coolant casing 10. However, in FIGS. 2 a-2 d, the cover 18 of the coolant casing 10 is not shown, which is illustrated by cut edges designated by 19 in the transition between the cover 18 and the end wall 26 and/or the end wall 28.

FIGS. 2 a and 2 c here show a top view onto the side walls 22 or 24 from the outside. FIG. 2 b shows a top view onto the base 20 from the outside.

In FIGS. 2 a and 2 c. it can be easily inferred that the base 20 has an undulating structure. In cross section, the base 20 has a bulging shape.

FIG. 2 b clearly shows that there are slot-shaped openings for holding the flat tubes of the tube-rib block 14 in the base.

From FIGS. 2 a and 2 c it can also be easily inferred—just like from FIG. 1 a—that the end of the side walls 22, 24 facing away from the tube-rib block 14 has, to a large extent, an essentially straight construction and has an indentation in the region in which the main port is arranged.

This indentation is provided, in particular, because the main port 40 here has correspondingly large dimensions.

From FIGS. 2 a and 2 c it can be inferred that the separating wall 32 does not extend up to the end of the side walls 22, 24 facing away from the tube-rib block. Nevertheless, this separating wall 32 divides the inner space 62 of the coolant casing 10 into two sub-chambers 64, 66.

This is enabled, because, after folding, the cover (not shown in FIGS. 2 a-2 d) projects so far into the unit 16 that it essentially contacts this separating wall 32.

FIG. 2 d shows a section view along line A-A from FIG. 2 b in a partial view.

In FIG. 2 d it is to be easily seen that the base with an undulating structure in the longitudinal direction 30 and with a bulged structure between the side walls 22, 24 forms insertion beveling for the flat tubes of the tube-rib block 14 through its undulating profile. The slots 60 are here arranged essentially in the region of the deeper positions of the undulating profile, as seen from the outside. Furthermore, by means of the undulating structure, a certain reinforcement effect is achieved in the region of the base.

In FIG. 2 d it is to be seen that the transition region 68 between the base 20 and the end wall 26 or 28 has a one-piece construction, also like the transition region 68 between the end wall 26 and the cover 18, wherein this transition region is indicated by the cut edge 19 but is not illustrated.

Furthermore, from FIGS. 2 c and 2 d it can be easily inferred that the end walls 26, 28 have lateral brackets or assemblies 72 in each of their end regions facing the side walls 22, 24.

These brackets 72 project in the longitudinal direction 30 or in the direction of the side walls 22, 24 away from the end wall 26, 28 and are soldered, for example, by means of solder-plating, to the side walls 22 or 24 on the outside or inside.

Alternatively, it could also be provided that such brackets 72 are provided on the side walls 22 and 24 at corresponding positions; these brackets are bent such that they run in the direction of the end wall plane and are soldered to the corresponding end wall 26, 28, particularly by means of solder-plating.

FIGS. 3 a-3 i show an example cover 18 of the coolant casing 10 that is cut out along the cut edges 19 from the one-piece part 16 or between the end walls 26 and 28.

Here, FIG. 3 a shows a side view of the cover 18, FIG. 3 b a top view of the cover 18, FIG. 3 c a three-dimensional view of the cover 18 from below, FIG. 3 d a section view along line C-C from FIG. 3 a, FIG. 3 e a partial section view along line D-D from FIG. 3 b, FIG. 3 f a section view along line E-E from FIG. 3 b, FIG. 3 g a section view along line F-F from FIG. 3 a, and FIG. 3 h a section view along line G-G from FIG. 3 a.

FIG. 3 i shows a perspective top view onto the cover according to FIG. 3 a in the region of the brackets arranged on the end side of the legs.

The cover 18 has, viewed in the longitudinal direction 30, an essentially U-shaped cross section, which is easily seen in FIGS. 3 c, 3 d, 3 f, 3 g, 3 h, and 3 i.

This U-shape has an approximately rectangular structure and is formed by two spaced-apart legs 82, 84, which could also be designated as flanges, and a connection section 86 connecting these two legs.

During the folding, this cover 18 is inserted (cf. FIG. 4) on the side of the unit 16 facing away from the base 20 into the unit 16 so that the connection section 86 faces this base and the legs 82, 84 project away from the connection section 16 in the direction facing away from the base.

Several brackets 88 extend from the legs 82, 84 of the U-shaped profile.

These brackets 88 have an arc-shaped structure in the embodiment example. The brackets 88 extend outward from the ends of the legs 82, 84 facing away from the connection region 86, i.e., specifically, they are bent. However, these brackets 88 could also have a bent profile instead of an arc-shaped profile.

End sections of the side walls 22, 24 are held in the brackets 88. The side walls 22, 24 can be soldered with the cover 18 in the region of these brackets, that is, in particular, through solder-plating. The cover 18 is soldered, in particular, so that a tight connection is produced, wherein, in particular, the solder-plating method could be used.

The brackets 88 are spaced apart from each other viewed in the longitudinal direction 30, so that, bracket-free regions are formed on the legs 82, 84 between adjacent brackets 88 in this longitudinal direction 30.

Based on the size of the opening 40, the cover has a bulge that is adapted essentially to the profile of the side walls 22, 24.

Furthermore, the cover has a recess 94. This recess runs transverse or perpendicularly to the longitudinal direction 30 approximately through the entire cover 18.

The recess 94, which here has an essentially rectangular cross section that, however, could also be provided with run-on beveling or that has a bulged structure, is used for holding the separating wall 32.

The recess 94 also simplifies, in particular, the soldering process in that the separating wall 32 is inserted there and can then be soldered. The soldering can be performed, in particular, by means of solder-plating.

FIGS. 4 and 5 show diagrams that indicate the folding of the one-piece part to form the closed unit 16 or 16 a of the coolant casing 10 or 12 according to the invention from FIGS. 1 a-3 i.

FIG. 4 shows a perspective diagram of a partially completed or folded one-piece unit 16 or 16 a. There, the opposing side walls 22 and 24 that are already folded, i.e., that are bent upward along the bending lines 22-1 and 24-1 are shown, and also the base 20 that here has a bulged structure.

The end wall 26, which is partially already bent upward along the bending line 26-1, connects in one piece to the base end 20-1 lying farther away in perspective. It is further connected in one piece to the cover 18, where it is folded along the bending line 18-1 relative to the end wall 26. The end wall 28 further connected in one piece to the cover 18 is bent opposite this along the bending line 18-2.

As FIG. 4 shows, the bulge 18-3 that is adapted essentially to the profile of the side walls 22, 24 is formed in the cover 18.

This one-piece unit 16, 16 a is formed from sheet metal, as FIG. 5 shows, that was initially punched (base plate 16 b) and optionally deep-drawn. The base plate 16 b, which already contains the pre-formed side parts 22, 24, the base 20, the end walls 26, 28, and the cover 18, is then folded along the bending lines 22-1, 24-1, 26-1. 18-1, and 18-2 to form the closed unit 16 or 16 a. The folded base plate 16 b is then soldered.

As an example, the folding of the end wall 26 will be described here briefly. To bring the end wall 26 into its position, during the course of the production process, it is bent upward about the folding or bending edge 26-1, so that it contacts the end of the already upward bent side walls 22, 24 with its lateral brackets 112, 114.

These brackets 112, 114 are then also bent so that they are arranged essentially parallel to the side walls 22, 24 and thus form regions for a solder connection with the side walls.

As is easy to infer from FIG. 5, triangular recesses are given in the regions 116, 118 that allow simplified bending.

Such brackets 112, 114 are also provided on the end wall 28.

In the base plate 16 b, one or more openings 60 for holding tubes, in particular, connection tubes, such as flat tubes, are formed before the folding in the region that forms the base 20 in the casing. The openings 60 for holding tubes could also be formed during the punching of the base plate 16 at the positions named above.

Before the folding of the base plate, this plate could also be processed by other shaping methods, in particular, drawing, especially deep-drawing, and/or hydro-shaping and/or mold pressing.

The heat exchanger, in particular, a cooler for a motor vehicle, has a tube-rib block and a casing or coolant casing according to the invention, wherein tubes of the tube-rib block in the region of the base of the casing open into this region.

Preferably, the casing 10, 12 is made from metal, in particular, from aluminum.

It shall also be noted that instead of a punched and then bent base plate 16 b, the use of casing profiles for producing the coolant casing 10 or 12 is also possible. 

1. A casing for holding a coolant for a heat exchanger for motor vehicles, comprising two side walls, two end walls, a cover, and a base arranged opposite the cover, in which one or more openings are provided for holding connecting tubes, wherein the casing is made from only one shaped, molded sheet metal part, wherein the shaped molded sheet metal part forms the two side walls, the two end walls, the cover and the base.
 2. The casing according to claim 1, wherein at least one of the side walls has an indentation, for holding a port.
 3. The casing according to claim 1, wherein the cover has a bulge that is adapted essentially to an indentation in the side walls.
 4. The casing according to claim 1, wherein one or more openings for holding connecting tubes are formed in the base.
 5. The casing according to claim 1, wherein the molded part has bending/flap or folding lines between two walls, across which the walls can be folded.
 6. The casing according to claim 1, wherein the shaped molded part is soldered.
 7. The casing according to claim 1, wherein at least one of the end walls has at least one bracket and/or assembly that is arranged, on the side and/or that can be angled.
 8. The casing according to claim 7, wherein the one or more brackets and/or assemblies are angled so that they are arranged essentially parallel to one of the side walls and/or are connected, by a solder connection with one of the side walls.
 9. The casing according to claim 1, wherein at least one, essentially triangular recess is formed in the molded part in a transition region between two walls.
 10. A heat exchanger, for a motor vehicle comprising a tube-rib block and a casing comprising two side walls, two end walls, a cover, and a base arranged opposite the cover, in which one or more openings are provided for holding connecting tubes, wherein the casing is made from only one shaped molded sheet metal part, wherein the shaped molded sheet metal part forms the two side walls, the two end walls, the cover and the base wherein the tubes of the tube-rib block open, in the region of the base of the casing into the casing.
 11. A method for producing a casing for holding a coolant, for a heat exchanger comprising producing a one-piece sheet metal part, by punching, wherein the one-piece sheet metal part includes walls that define an inner space of the casing and that are two side walls, two end walls, a cover, and a base arranged opposite the cover; and shaping the one-piece sheet metal part by bending or folding along given bending or folding lines to form an essentially closed casings; and, solder-plating the shaped, one-piece sheet metal part, wherein the casing is formed.
 12. The method according to claim 11, wherein shaping includes folding across an end wall or across two end walls.
 13. The method according to claim 12, wherein the one-piece sheet metal part is processed before or after the folding by a drawing method, and/or hydro-shaping, and/or mold pressing.
 14. The method according to claim 11, wherein the one-piece sheet metal part, in a region of the one-piece sheet metal part that forms the base in the casing, one or more openings are formed for holding connecting tubes.
 15. The method according to claim 14, wherein the one or more openings for holding tubes are formed before shaping the one-piece sheet metal part.
 16. The method according to claim 14, wherein one or more connecting tubes are inserted into the one or more openings.
 17. The method according to claim 16, wherein the one or more tubes are inserted into the one or more openings before shaping the one-piece sheet metal part. 